Structural panel for an appliance having stamped components and method therefor

ABSTRACT

An operable panel for an appliance includes a metallic outer wrapper having a perimetrical wrapper edge that partially defines a perimetrical breaker channel, an inner liner and a plurality of corner brackets disposed proximate the perimetrical wrapper edge. Each corner bracket cooperates with the perimetrical wrapper edge to fully define the perimetrical breaker channel. A trim breaker is adhered to the metallic outer wrapper and the corner brackets at the perimetrical breaker channel and having a liner channel that receives a portion of the inner liner. The trim breaker extends between the inner liner and the outer wrapper. An insulation material is disposed within an insulating cavity defined between the inner liner and the outer wrapper.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 16/308,979 filed Dec. 11, 2018, entitled STRUCTURAL PANEL FOR ANAPPLIANCE HAVING STAMPED COMPONENTS AND METHOD THEREFOR, which is anational stage of International Application No. PCT/US2016/054121 filedSep. 28, 2016, entitled STRUCTURAL PANEL FOR AN APPLIANCE HAVING STAMPEDCOMPONENTS AND METHOD THEREFOR, the entire disclosures of which arehereby incorporated herein by reference.

FIELD OF THE DEVICE

The device is in the field of insulation structures for appliances, andmore specifically, a multi-component structural panel for an appliancehaving at least one stamped component.

SUMMARY

In at least one aspect, an operable panel for an appliance includes ametallic outer wrapper having a perimetrical wrapper edge that partiallydefines a perimetrical breaker channel, an inner liner and a pluralityof corner brackets disposed proximate the perimetrical wrapper edge.Each corner bracket cooperates with the perimetrical wrapper edge todefine the perimetrical breaker channel. A trim breaker is adhered tothe metallic outer wrapper and the corner brackets at the perimetricalbreaker channel and includes a liner channel that receives a portion ofthe inner liner. The trim breaker extends between the inner liner andthe outer wrapper. An insulation material is disposed within aninsulating cavity defined between the inner liner and the outer wrapper.

In at least another aspect, a method for forming a vacuum insulatedstructure for an appliance includes stamping a first metallic sheet intoa flat liner pattern that corresponds to an inner liner for anappliance. The inner liner has a plurality of liner walls and aperimetrical liner tab. The flat liner pattern is shaped into the innerliner. A second metallic sheet is stamped into a flat wrapper patternthat corresponds to an outer wrapper for an appliance. The outer wrapperhas a plurality of wrapper walls and a perimetrical wrapper edge. Theflat wrapper pattern is shaped into the outer wrapper. A trim breaker isformed having a liner channel and a wrapper channel. The perimetricalliner tab and the perimetrical wrapper edge are secured with the linerand wrapper channels, respectively. An insulating material is disposedwithin an insulating cavity formed between the inner liner and the outerwrapper.

In at least another aspect, a method for forming a vacuum insulatedstructure for an appliance includes forming a first planar sheet into aninner liner. A second planar sheet is formed into an outer wrapperhaving a plurality of wrapper walls and a wrapper edge that at leastpartially defines a perimetrical breaker channel. A trim breaker isformed having a liner channel for receiving a portion of the inner linerand a wrapper channel for seating within the perimetrical breakerchannel. The inner liner is secured within the liner channel and thewrapper channel is placed within the perimetrical breaker channel. Aninsulating material is disposed within an insulating cavity formedbetween the inner liner and the outer wrapper.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artupon studying the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front elevational view of an appliance having operablepanels that are formed using an aspect of the method for forming avacuum insulated structure;

FIG. 2 is a front perspective view of the drawer panel of the applianceof FIG. 1;

FIG. 3 is a rear perspective view of the drawer panel of FIG. 2;

FIG. 4 is an exploded perspective view of the drawer panel of FIG. 3with the drawer glides removed;

FIG. 5 is a cross-sectional view of the drawer panel of FIG. 3 takenalong line V-V;

FIG. 6 is an enlarged cross-sectional view of the drawer panel of FIG. 5taken at area VI, with the gasket removed;

FIG. 7 is an enlarged perspective view of the drawer panel;

FIG. 8 is a partially exploded perspective view of the outer wrapper ofFIG. 7;

FIG. 9 is a perspective view of the corner bracket of FIG. 8;

FIG. 10 is an enlarged perspective view of the corner detail of thedrawer panel of FIG. 3;

FIG. 11 is a plan view of an aspect of a stamped metallic panelincluding guide lines that can be shaped to form an aspect of an outerwrapper of an operable panel for an appliance;

FIG. 12 is a cross-sectional view of an aspect of an operable panelincorporating a stamped inner liner that includes an injection moldedportion proximate a trim breaker;

FIG. 13 is a schematic cross-sectional view of an aspect of the operablepanel for an appliance exemplifying an aspect of a trim breaker havingelongated legs;

FIG. 14 is a partially exploded view of an aspect of an inner liner foran operable panel for an appliance showing a stamped inner liner and aninjection molded end piece;

FIG. 15 is a schematic linear flow diagram illustrating a method forforming a vacuum insulated structure for an appliance; and

FIG. 16 is a schematic linear flow diagram illustrating a method forforming a vacuum insulated structure for an appliance.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the device as oriented in FIG. 1. However, it isto be understood that the device may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of theinventive concepts defined in the appended claims. Hence, specificdimensions and other physical characteristics relating to theembodiments disclosed herein are not to be considered as limiting,unless the claims expressly state otherwise.

As illustrated in FIGS. 1-6, reference numeral 10 generally refers to anoperable panel for an appliance 12, where the operable panel 10 can bein the form of a rotating door 14 or a slidable drawer 16 for theappliance 12 to define open and closed positions of various interiorcompartments 18 of the appliance 12. According to the various aspects ofthe device, the operable panel 10 for the appliance 12 can include ametallic outer wrapper 20 having a perimetrical wrapper edge 22 thatpartially defines a perimetrical breaker channel 24. The operable panel10 can also include an inner liner 26. It is contemplated that themetallic outer wrapper 20 and the inner liner 26 can be coupled togetherto define an insulating cavity 28 therebetween. A plurality of cornerbrackets 30 can be disposed proximate the perimetrical wrapper edge 22,where each corner bracket 30 cooperates with the perimetrical wrapperedge 22 to fully define the perimetrical breaker channel 24 of the outerwrapper 20. Typically, the corner brackets 30 will be disposed in theouter corners 32 of the outer wrapper 20, such that where the operablepanel 10 is rectangular, four corner brackets 30 will be disposed ineach of the four outer corners 32 of the outer wrapper 20. A trimbreaker 34 is adhered to the metallic outer wrapper 20 and the cornerbrackets 30 at the perimetrical breaker channel 24. The trim breaker 34includes a liner channel 36 that receives a portion of the inner liner26. The trim breaker 34 is adapted to extend between the inner liner 26and the outer wrapper 20 to substantially seal the edges of the outerwrapper 20 and the inner liner 26 and enclose the insulating cavity 28defined therebetween. The trim breaker 34 is adapted to engage theperimetrical breaker channel 24 defined by the outer wrapper 20 and theplurality of corner brackets 30.

Referring again to FIGS. 3-8, a flexible gasket 50 can be disposedwithin a gasket channel 52 defined within the trim breaker 34. It iscontemplated that the gasket channel 52 is positioned proximate awrapper channel 54 that is adapted to be disposed within theperimetrical breaker channel 24. The wrapper channel 54 of the trimbreaker 34 is adapted to seat within the perimetrical breaker channel 24of the outer wrapper 20 and the corner brackets 30. It is contemplatedthat the trim breaker 34 can include a U-shaped channel that defineseach of the wrapper channel 54 and the gasket channel 52. In such anembodiment, one surface of the U-shaped channel of the trim breaker 34defines the wrapper channel 54 and the opposing surface of the U-shapedchannel defines the gasket channel 52. Accordingly, it is contemplatedthat the outward extending surface of the U-shaped channel can definethe wrapper channel 54 that seats within the perimetrical breakerchannel 24 of the metallic outer wrapper 20. Conversely, the inwardlyextending surface of the U-shaped channel is adapted to receive aportion of the gasket 50 such that the gasket 50 seats within the gasketchannel 52 of the trim breaker 34. Through the use of the U-shapedchannel, it is contemplated that at least a portion of the gasket 50 canbe positioned and supported within the channel volume defined by theperimetrical breaker channel 24 of the metallic outer wrapper 20 and thecorner brackets 30.

Referring now to FIGS. 2-9, it is contemplated that the various cornerbrackets 30 can include an outer engagement surface 60 that engages aninterior surface 62 of the outer wrapper 20 at each of the outer corners32. Each corner bracket 30 can include a plurality of adhesion grooves64 defined within the engagement surface 60. Each of these adhesiongrooves 64 can serve to retain an adhesive 116 therein such that whenthe engagement surface 60 of the corner bracket 30 engages the interiorsurface 62 of the outer wrapper 20, adhesive 116 disposed within each ofthe adhesion grooves 64 can serve to apply the adhesive 116 to form asecure and hermetically sealed engagement between each corner bracket 30and the interior surface 62 of the outer wrapper 20. This engagementalso serves to secure a channel portion 66 of each corner bracket 30 inalignment with the remainder of the perimetrical breaker channel 24 ofthe outer wrapper 20. This engagement serves to define or fully definethe perimetrical breaker channel 24 within which the wrapper channel 54of the trim breaker 34 can seat. In addition to the channel portion 66,each corner bracket 30 can include a structural body 68 that engages aplurality of interior surfaces 62 defined within the outer corner 32 ofthe outer wrapper 20.

By way of example, and not limitation, when various aspects of the outerwrapper 20 are formed, a flat wrapper pattern 80 that is stamped withina metallic sheet that can be folded upward to form the various contoursof the outer wrapper 20. In such an embodiment, each edge and theportions of the perimetrical breaker channel 24 within each edge of theouter wrapper 20 can be formed from a separate wing 82 defined withinthe flat wrapper pattern 80. As these wings 82 are folded upward, a seam84 is formed along each outer corner 32 where two adjacent wings 82 ofthe flat wrapper pattern 80 engage one another. It is contemplated thateach corner bracket 30 engages various interior surfaces 62 of each ofthese wings 82 to reinforce the outer corner 32 of the outer wrapper 20and also reinforce the perimetrical breaker channel 24 of the outerwrapper 20.

According to the various embodiments, as exemplified in FIGS. 5-11, theadhesive 116 disposed within the adhesion grooves 64 of each cornerbracket 30 can be deposited proximate the seam 84 to fill and seal andpotentially hermetically seal each of these seams 84 to form secureconnections between each of the wings 82 that form the outer corners 32of the outer wrapper 20. To further reinforce the seam 84 between theadjacent wings 82 of the flat wrapper pattern 80, the seam 84 can befurther sealed through a secondary process to re-strike each outercorner 32 of the outer wrapper 20 and close any visible gaps that appearas a result of the seam 84. Such re-striking process can be performedthrough pinching, welding, grinding, adhering, combinations thereof, andother similar methods that can close and seal the seam 84 to make theseam 84 substantially air-tight and unnoticeable. Accordingly, the outerwrapper 20 can appear as a substantially monolithic member, lackingvisible seams 84 within portions of the exterior surface 86 of the outerwrapper 20.

Referring again to FIGS. 1-10, it is contemplated that the operablepanel 10 described herein can include a panel for a rotationallyoperable door 14 that can include a hinge assembly 90 that is attachedto the outer wrapper 20, the trim breaker 34 and/or the inner liner 26.It is contemplated that the hinge assembly 90 can extend from theoperable panel 10, and typically the outer wrapper 20 and extend to acabinet structure 92 of the appliance 12. It is contemplated that such ahinge assembly 90 can be attached to a reinforcing structure disposedproximate the interior surface 62 of the outer wrapper 20 thatsubstantially prevents deflection at the outer wrapper 20 and otherportions of the operable panel 10 during use of the appliance 12. It iscontemplated that the operable panel 10 can be a panel for a drawer 16where a drawer glide assembly 94 is attached to at least one of theinner liner 26 and the outer wrapper 20. In such an embodiment, thedrawer glide assembly 94 can be adapted to extend from the operablepanel 10 to a portion of the cabinet structure 92 to secure the operablepanel 10 thereto. As with the hinge assembly 90, the drawer glideassembly 94 can include a reinforcing structure disposed proximate theinterior surface 62 of the outer wrapper 20 to prevent bending, warpingand other deflection of the operable panel 10 during use of theappliance 12.

Referring again to FIGS. 2-6, it is contemplated that an insulationmaterial 100 can be disposed within the insulating cavity 28 definedbetween the inner liner 26, the outer wrapper 20 and trim breaker 34extending therebetween. Various insulation materials 100 can be includedwithin the insulating cavity 28. Such insulating materials can include,but are not limited to, microspheres, nanospheres, silica-typematerials, granulated insulation material, powder-based insulationmaterial, foam insulation, vacuum insulated panels, combinationsthereof, other similar insulating materials. It is also contemplatedthat the engagement between the outer wrapper 20, the inner liner 26,and the trim breaker 34 can form a substantially hermetic seal. Thishermetic seal can allow for the expression or expulsion of gas fromwithin the insulating cavity 28 such that the operable panel 10 can bemanufactured to include an at least partial vacuum within the insulatingcavity 28 to define the operable panel 10 as a self-contained vacuuminsulation structure. In such an embodiment, a vacuum port may bedisposed within a portion of the operable panel 10 such that gas can beexpressed or expelled through the vacuum port and sealed to maintain theat least partial vacuum within the insulating cavity 28.

Referring again to FIGS. 1-10, it is contemplated that the inner liner26 can be formed from a first metallic sheet 110 that is stamped into aflat liner pattern 112, or stamped into the shape of a metallic innerliner 26 for use in the operable panel 10. It is also contemplated thatthe inner liner 26 can be formed from the plastic-type material that canbe molded, stamped, or otherwise formed into the shape of the innerliner 26. The outer wrapper 20 can also be made of various materialsthat can include, but are not limited to, metal, plastic, combinationsthereof and other similar materials. Typically, the outer wrapper 20will be formed from a second metallic sheet 114 such that the innerliner 26 and outer wrapper 20 are each metallic sheets that form theoperable panel 10. The trim breaker 34 can be in the form of aninjection molded piece that is injection molded around portions of theinner liner 26 and the outer wrapper 20.

According to the various embodiments, as exemplified in FIGS. 1-10, itis also contemplated that the trim breaker 34 can be a separately moldedplastic member that can be attached to the inner liner 26 and outerwrapper 20 through adhesives 116, welding, or other similar process tosecure the trim breaker 34 to the inner liner 26 and outer wrapper 20.It is contemplated that when the trim breaker 34 is attached to theouter wrapper 20, an adhesive 116 can be placed within the perimetricalbreaker channel 24 and the wrapper channel 54 of the trim breaker 34 canbe set within the perimetrical breaker channel 24 and secured thereinthrough the adhesive 116. The adhesive 116 used in attaching the trimbreaker 34 to the inner liner 26 and outer wrapper 20 can assist informing the hermetic seal of the operable panel 10. It is alsocontemplated that in forming the inner liner 26 and/or outer wrapper 20,at least one wrapper wall 120 or liner wall 122 can be in an injectionmolded member (shown in FIG. 12) that defines at least a portion of theinner liner 26 and/or the outer wrapper 20 and also serves to define aportion of the trim breaker 34 extending therebetween. In order toincrease and strengthen the engagement between the trim breaker 34 anthe inner liner 26 and/or the outer wrapper 20, the trim breaker 34 caninclude an elongated flange 124 (shown in FIG. 13) that provides a moreextensive surface engagement between the trim breaker 34 and at leastone of the inner liner 26 and the outer wrapper 20. This added surfaceengagement can serve to enhance the hermetic seal defined by theoperable panel 10 such that a more complete vacuum can be defined withinthe insulating cavity 28 of the operable panel 10.

Referring now to FIGS. 1-15, having described various aspects of theoperable panel 10 and construction thereof, a method 400 is disclosedfor forming a structural panel for an appliance 12. According to themethod 400, a first metallic sheet 110 can be stamped into the shape ofa flat liner pattern 112 that corresponds to the inner liner 26 of anappliance 12 (step 402). The flat liner pattern 112 can include variousgeometries that can correspond to a plurality of liner walls 122 and aperimetrical liner tab 130, where the perimetrical liner tab 130 can beadapted to engage with a liner channel 36 at the trim breaker 34 duringassembly of the operable panel 10. Once the flat liner pattern 112 isformed, the flat liner pattern 112 can be shaped into the shape of theinner liner 26 (step 404).

According to the various embodiments, it is contemplated that the innerliner 26 can be stamped directly into the shape of an inner liner 26, orat least a portion of the inner liner 26, without necessarily includingthe step of forming the flat liner pattern 112 through a separatestamping process. Typically, where the liner pattern 112 is directlystamped into the shape of the inner liner 26, the material of the innerliner 26 is a more flexible and pliable material such as plastic,polymers and other similar materials that can be stamped withoutsignificant wrinkling, bunching or other unwanted deformations.

Referring again to FIGS. 1-15, according to the method 400, a secondmetallic sheet 114 can be stamped into a flat wrapper pattern 80 thatcorresponds to an outer wrapper 20 for an appliance 12 (step 406). Asdiscussed above, the outer wrapper 20 includes a plurality of wrapperwalls 120 and a perimetrical wrapper edge 22. It is contemplated thatthe perimetrical wrapper edge 22 can define at least part of theperimetrical breaker channel 24 that receives the wrapper channel 54 ofthe trim breaker 34. Once the flat wrapper pattern 80 is formed, theflat wrapper pattern 80 can be shaped into the form of the outer wrapper20 (step 408).

According to the various embodiments and aspects of the various methods,the steps of stamping first and second metallic sheets 110, 114 into theflat liner pattern 112 and flat wrapper pattern 80, respectively, caninclude disposing guide lines 140 within the flat liner and flat wrapperpatterns 112, 80. It is contemplated that these guide lines 140 cancorrespond to edges and corners of the plurality of liner walls 122 andedges of the plurality of wrapper walls 120. The use of guide lines 140can also assist in the forming step of the inner liner 26 and outerwrapper 20, such that clean and precise edges can be formed as the innerliner 26 and outer wrapper 20 are folded into their respective finalshapes.

Referring again to FIGS. 1-15, according to the method 400, a trimbreaker 34 is formed, where the trim breaker 34 includes a liner channel36 and wrapper channel 54 (step 410). After the trim breaker 34 isformed, the perimetrical liner tab 130 and the perimetrical wrapper edge22 can be secured to the liner and wrapper channels 36, 54 of the trimbreaker 34, respectively (step 412). According to the variousembodiments, it is contemplated that the trim breaker 34 can bepreformed and the inner liner 26 and outer wrapper 20 can be adhered,welded, or otherwise secured to the trim breaker 34. It is alsocontemplated that the trim breaker 34 can be injection molded aroundportions of the inner liner 26 and outer wrapper 20 to form a securestructure between these components.

According to various embodiments, it is contemplated that portions ofthe inner liner 26 and/or outer wrapper 20 can include injection moldedor separately formed plastic components that can be integrated with thetrim breaker 34 and attached to portions of the inner liner 26 and outerwrapper 20.

As exemplified in FIGS. 12 and 14, the inner liner 26 can include anelongated band that is stamped or otherwise shaped into a profile of theinner liner 26. At least one of a top and bottom cap 150 of the innerliner 26 can be either injection molded or premolded and attached to thestamped portion of the inner liner 26 to fully define the shape of theinner liner 26. It is contemplated that this injection molded portion ofthe inner liner 26 can either be attached to the trim breaker 34 or canbe injection molded as part of the trim breaker 34. In such anembodiment, the stamped portion of the inner liner 26 can define a mainbody 152 of the inner liner 26. The end portions 154 of the inner liner26, which may be injection molded or otherwise formed from plastic orother polymer-type material, can be a cap 150 attached to the endportions 154 of the main body 152 of the inner liner 26. It is alsocontemplated that the cap 150 attached to the main body 152 of the innerliner 26 can be in the form of a sheet member made of metal and/orplastic that is adhered to the edge of the main body 152 of the innerliner 26. Accordingly, the caps 150 can be in the form of atwo-dimensional or three-dimensional shape that can be attached to themain body 152 of the inner liner 26.

According to the various embodiments, it is contemplated that the trimbreaker 34 can be injection molded, overmolded or otherwise formed toonly one of the inner liner 26 and the outer wrapper 20. The other ofthe inner liner 26 and outer wrapper 20 can then be adhered, fastened,or otherwise attached to the trim breaker 34 to form the operable panel10. By way of example, and not limitation, the trim breaker 34 can beovermolded onto a portion of the inner liner 26 proximate theperimetrical liner tab 130. The outer wrapper 20 can then be adhered tothe trim breaker 34 through the engagement of the wrapper channel 54 ofthe trim breaker 34 and the perimetrical breaker channel 24 of the outerwrapper 20.

Referring again to FIGS. 1-15, an insulation material 100 can bedisposed within the insulating cavity 28 formed within the inner liner26 and the outer wrapper 20 (step 414). Once the operable panel 10 issubstantially formed, a gasket 50 can be disposed within a gasketchannel 52 of the trim breaker 34, where the gasket channel 52 isdisposed proximate the wrapper channel 54 of the trim breaker 34 (step416).

Referring again to FIGS. 7-10, according to various aspects of themethod 400, as the flat wrapper pattern 80 is shaped, various cornerbrackets 30 can be disposed against an interior surface 62 of the outerwrapper 20 at each outer corner 32, respectively. It is contemplatedthat the outer wrapper 20 and corner brackets 30 cooperate to define theperimetrical channel of the outer wrapper 20. During formation of theouter wrapper 20, the corner brackets 30 can be positioned on the flatwrapper pattern 80 and then the flat wrapper pattern 80 can be formedaround the brackets. Alternatively, the outer wrapper 20 can be formedand then the corner brackets 30 can be disposed in the outer corners 32of the pre-formed outer wrapper 20. It is further contemplated that thecorner brackets 30 can be pre-formed to a desired shape, or can beinjection molded within the outer corners 32 of the outer wrapper 20.Where the corner brackets 30 are pre-formed, an adhesive 116 istypically included within the adhesion grooves 64 defined within theengagement surface 60 of each corner bracket 30, as described above.

Referring again to FIG. 10, various aspects of the method can include astep of sealing the outer corners 32 proximate the outer wrapper 20 ofthe corner brackets 30. In such an embodiment, two distinct edges of theflat wrapper pattern 80 defined by wings 82 of the flat wrapper pattern80 can define a seam 84 at each outer corner 32. It is contemplated thatthe corner brackets 30 can be entirely disposed within the insulatingcavity 28 to support the outer corner 32 of the outer wrapper 20 duringsealing of each outer corner 32. As discussed above, sealing the outercorners 32 can include welding, striking, the use of adhesives 116,combinations thereof, and other similar methods that can seal twoadjacent wings 82 of the flat wrapper pattern 80.

Referring now to FIGS. 1-14 and 16, a method 500 is disclosed forforming a structural panel for an appliance 12. According to the method500, a first planar sheet is formed into the shape of an inner liner 26(step 502). As discussed above, the first planar sheet can be metallic,plastic, other polymer-type material, combinations thereof, and othersimilar materials that can be used to shape the inner liner 26. Theexact forming process used to form the inner liner 26 can depend uponthe material of the first planar sheet. A second planar sheet is formedinto the shape of an outer wrapper 20 (step 504). As discussed above,the outer wrapper 20 can include a plurality of wrapper walls 120 and awrapper edge 22 that at least partially defines the perimetrical breakerchannel 24. Typically, the second planar sheet will be a metallic panelthat is stamped and then folded into the shape of the outer wrapper 20.It is contemplated that other materials can be used to form the outerwrapper 20, such as plastic, other polymer materials, composites,combinations thereof, and other similar panel-forming materials. Oncethe inner liner 26 and outer wrapper 20 are formed, a trim breaker 34 isformed having a liner channel 36 for receiving a portion of the innerliner 26 and a wrapper channel 54 for seating within the perimetricalbreaker channel 24 (step 506). The inner liner 26 is then secured withinthe liner channel 36 and the wrapper channel 54 is placed within theperimetrical breaker channel 24 (step 508). An insulation material 100is also disposed within the insulating cavity 28 formed between theinner liner 26 and outer wrapper 20 (step 510). It is contemplated thatthe insulation material 100 can be disposed within the insulating cavity28 at various steps within the formation of the operable panel 10. It iscontemplated that the operable panel 10 can be manufactured to includean insulation port through which insulation material 100 can be disposedafter the inner liner 26, outer wrapper 20 and trim breaker 34 areattached together to form the structure of the operable panel 10. It isalso contemplated that the insulation material 100 can be disposedwithin the outer wrapper 20 and then the trim breaker 34 and inner liner26 can be attached to the outer wrapper 20 to contain the insulationmaterial 100 within the now-formed insulating cavity 28.

According to the various embodiments, the various aspects of theoperable panel 10 and the various aspects of the methods describedherein can be used to form operable panels 10 for various appliances 12.Such appliances 12 can include, but are not limited to, refrigerators,freezers, dishwashers, laundry appliances, ovens, coolers, waterheaters, and other similar appliances 12 that include an insulationsystem.

As discussed above, the inner liner 26, outer wrapper 20 and trimbreaker 34 can be made of various materials that can be stamped, formed,folded or otherwise shaped into the final form of the operable panel 10.It is contemplated that the exact material used for these components candictate the methods and sequence of steps that may be used to form theinner liner 26, outer wrapper 20 and trim breaker 34. Where a metallicsheet is used for the inner liner 26 and/or outer wrapper 20, themetallic sheet will typically be stamped into a particular pattern andthen the pattern will be bent or otherwise shaped into the final form orsubstantially the final form of the inner liner 26 and/or outer wrapper20. It is contemplated that these operations can be used in conjunctionwith various plastic forming, injection molding, overmolding or plasticattaching processes that can fully form the shape of the inner liner 26and/or the outer wrapper 20. Where the inner liner 26 and/or outerwrapper 20 are formed of plastic, a single stamping, heat forming,molding, or other shaping process can be used to form the inner liner 26and/or outer wrapper 20. Such plastic materials can be shaped, bent, orotherwise formed more easily and without the occurrence of wrinkling,pinching or other unwanted physical features occurring within the innerliner 26 and/or the outer wrapper 20.

It will be understood by one having ordinary skill in the art thatconstruction of the described device and other components is not limitedto any specific material. Other exemplary embodiments of the devicedisclosed herein may be formed from a wide variety of materials, unlessdescribed otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the device as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present device. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present device, and further it is to be understoodthat such concepts are intended to be covered by the following claimsunless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodimentsonly. Modifications of the device will occur to those skilled in the artand to those who make or use the device. Therefore, it is understoodthat the embodiments shown in the drawings and described above is merelyfor illustrative purposes and not intended to limit the scope of thedevice, which is defined by the following claims as interpretedaccording to the principles of patent law, including the Doctrine ofEquivalents.

What is claimed is:
 1. A method for forming a structural panel for anappliance, the method comprising steps of: stamping a first metallicsheet into a flat liner pattern that corresponds to an inner liner forthe appliance, the inner liner having a plurality of liner walls and aperimetrical liner tab; shaping the flat liner pattern into the innerliner; stamping a second metallic sheet into a flat wrapper pattern thatcorresponds to an outer wrapper for the appliance, the outer wrapperhaving a plurality of wrapper walls and a perimetrical wrapper edge;shaping the flat wrapper pattern into the outer wrapper; forming a trimbreaker having a liner channel and a wrapper channel; securing theperimetrical liner tab and the perimetrical wrapper edge with the linerand wrapper channels, respectively; and disposing an insulating materialwithin an insulating cavity formed between the inner liner and the outerwrapper wherein the step of shaping the flat wrapper pattern includesdisposing corner brackets against an interior surface of the outerwrapper at each wrapper corner, respectfully, wherein the outer wrapperand the corner brackets cooperate to define a perimetrical breakerchannel.
 2. The method of claim 1, wherein the steps of stamping thefirst and second metallic sheets each include disposing guide lineswithin the flat liner and flat wrapper patterns, wherein the guide linescorrespond to edges of the plurality of liner walls and edges of theplurality of wrapper walls.
 3. The method of claim 1, wherein theperimetrical breaker channel is defined within the perimetrical wrapperedge, and wherein the wrapper channel of the trim breaker seats withinthe perimetrical breaker channel of the outer wrapper.
 4. The method ofclaim 1, further comprising the step of: disposing a gasket within agasket channel of the trim breaker, wherein the gasket channel ispositioned proximate the wrapper channel.
 5. The method of claim 4,wherein the trim breaker includes a U-shaped channel, wherein onesurface of the U-shaped channel defines the wrapper channel and anopposing surface of the U-shaped channel defines the gasket channel. 6.The method of claim 1, further comprising a step of: sealing the wrappercorners proximate the corner brackets, wherein two distinct edges of theflat wrapper pattern define each wrapper corner, wherein the cornerbrackets are entirely disposed within the insulating cavity.
 7. Themethod of claim 1, wherein each corner bracket includes an engagementsurface that defines a plurality of adhesion grooves that retain anadhesive therein, and wherein the adhesive at least partially securesthe corner bracket to the interior surface of the outer wrapper.
 8. Themethod of claim 1, wherein the insulating material is a vacuum insulatedpanel.
 9. A method for forming a structural panel for an appliance, themethod comprising steps of: forming a first planar sheet into an innerliner; forming a second planar sheet into an outer wrapper having aplurality of wrapper walls and a wrapper edge that at least partiallydefines a perimetrical breaker channel; forming a trim breaker having aliner channel for receiving a portion of the inner liner and a wrapperchannel for seating within the perimetrical breaker channel; securingthe inner liner within the liner channel and placing the wrapper channelwithin the perimetrical breaker channel; and disposing an insulatingmaterial within an insulating cavity formed between the inner liner andthe outer wrapper wherein the step of forming the outer wrapper includesdisposing a plurality of corner brackets within outer corners of theouter wrapper, wherein the plurality of corner brackets and the wrapperedge cooperate to define the perimetrical breaker channel.
 10. Themethod of claim 9, wherein the step of securing the wrapper channelwithin the perimetrical breaker channel includes applying an adhesivewithin the perimetrical breaker channel and adhering the wrapper channelwithin the perimetrical breaker channel.
 11. The method of claim 9,wherein the step of forming the second planar sheet includes stampingthe second planar sheet to include guide lines, wherein the guide linescorrespond to the plurality of wrapper walls.
 12. The method of claim 9,further comprising the step of: disposing a gasket within a gasketchannel of the trim breaker, wherein the gasket channel is positionedproximate the wrapper channel.
 13. The method of claim 12, wherein thetrim breaker includes a U-shaped channel, wherein one surface of theU-shaped channel defines the wrapper channel and an opposing surface ofthe U-shaped channel defines the gasket channel.
 14. The method of claim9, further comprising a step of: sealing the outer corners proximate theplurality of corner brackets, wherein two distinct edges of the secondplanar sheet define each outer corner, wherein the plurality of cornerbrackets are entirely disposed within the insulating cavity.
 15. Amethod for forming a structural panel for an appliance, the methodcomprising steps of: forming a first planar sheet into an inner liner;forming a second planar sheet into an outer wrapper having a pluralityof wrapper walls and a wrapper edge that at least partially defines aperimetrical breaker channel; disposing a plurality of corner bracketswithin outer corners of the outer wrapper, wherein the plurality ofcorner brackets and the wrapper edge cooperate to define theperimetrical breaker channel; forming a trim breaker having a linerchannel for receiving a portion of the inner liner and a wrapper channelfor seating within the perimetrical breaker channel; securing the innerliner within the liner channel and placing the wrapper channel withinthe perimetrical breaker channel; disposing a gasket within a gasketchannel of the trim breaker, wherein the gasket channel is positionedproximate the wrapper channel; and disposing an insulating materialwithin an insulating cavity formed between the inner liner and the outerwrapper.
 16. The method of claim 15, wherein the step of securing thewrapper channel within the perimetrical breaker channel includesapplying an adhesive within the perimetrical breaker channel andadhering the wrapper channel within the perimetrical breaker channel.17. The method of claim 15, wherein the step of forming the secondplanar sheet includes stamping the second planar sheet to include guidelines, wherein the guide lines correspond to the plurality of wrapperwalls.
 18. The method of claim 15, wherein the insulating material is avacuum insulated panel.